Manufacture of artificial-stone structures.



P. E. DENWELLE.

MANUFACTURE OF ARTIFICIAL STONE STRUCTURES.

APPLICATION FILED ocr. 20. 1915.

1,212,331. Patented Jan. 16.1917

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43) M fcjww PAUL E; DENIVELLE, OF NEW YORK, N. Y.

MANUFACTURE OF ARTIFICIAL-SCION E STRUCTURES.

Specification of Letters Patent.

Patented Jan. 16, 1917.

Application filled October 20, 1915. Serial No. 56,819.

To all whom it may concern:

Be it known that I, PAUL E. Demvunuc,

a. citizen of the United States, residing at New York}, in tho countyof New York and State of how York, have invented new and useful Improvements in the Manufacture of Artificial-Stone Structures, of which the following is a specification.

This invention con'iprehends a process to be used in the manufacture of an artificial stone simulating travcrtin stone or marble and adapted to be used especially for its architectural and decorative serials-e ell'ect.

The embodiment of the invention may be considered in two aspects: (A) representing the method as practised for casting separate articles, such as columns, capitals, figures, etc, later to be set in place. (ll) represent ing the method as practised [or surfacing and finishing structures already in place, such as walls, cornices. 01.

The first method cmhraces the application of colored plastic material or ingredients, such as Portland cement, plaster of Paris, Keencs cement, magnesitc and water or other liquid substance with or without aggregates to an upturned negative viorm, or mold of existing type, of wood, plaster, cement, etc, wherein these colored materials are. so applied before the final set or crystallization of the mass, in avariety of progressive steps consecutively, as to produce in the cast or positive taken from said mold, form, etc,

automatically as a result of the progressive stops and special application, a certain'riatoll form of texture porousness in simulation of. a stone known as travortin or Roman travcrtin. This process has to do mainly with producin' or obtaining a surface especially desirob c for reproducing in architectural and decorative eflect; this method of use and eflect being an innova-- 'tion.

' The. second method involves the use of the above colored materials in a certain definite and novel manner during their direct application to a wall or ceiling, or similar surface, rind before the set or crystallization is comletc, in order that the resulting surface may have a. colored striated or )Ol'OllS surface in simulation of travertin or Roman travertin texture or stone of similar striated porousnoss; this form of use and effect being an innovation.

The drawings illustrate the application of the invention simply in a schematic manner.

Figure 1 illustrates one form of process. F g. 2 represents another form of process. Fig. 3 is a pcrs cctive of a device suitable for (producing tie veining effect on or in a moi I In practising the invention under method (A) 1 proceed as follows: I employ a mold or negative, as '2, having the surface or contour of the article to be reproduced.

[a a toting.

(1.) The mold form or upturned surface or negative is prepared and greased or treatcd with any suitable isolator to produce a smooth surface that imparts no influence. to the nature. of porosity expected in the cast.

Vci'rring.

(2.) A mixture of colored cement and water, or other liquid, or similar substance in' a semi-liquid state is poured-over the sur ace of the form or mold from a receptacle as C, or openings (individual or a series of nozzles or openings that produce by gravity) in such a. way that ifv pouring is repeatrd back and forth over the form surface, it will pro duce a series of thin lines of the mixture, indicated at 3. This can be repeated inscvral colors. This is for the pur lnhic uf producing veins of one or more colors ang]v for the purpose of leaving smooth striptrd lines 0d the surface of the finished cast or positiyc when taken from said form. It is also for the purpose of providing an interruption to the finished ell'ect in the degree-0t porousness to be obtained by applying the next coating. Stippling.

(3.) Sometimes this vcining is stippled with a stiff wire. brush to interrupt the veining and give a serrated edge effect to the veins.

Forming pockets.

is distributed,

too

thereon. This is for the purpose of preventing the next coating of step (5) from ontirely enveloping, by gravity or seepage, the intent of said operation (4). Coating 4 is so applied and is of such loose lumpy consistency as to provide in the finished surf-are of the cast a porous, pocket-like appearance between the striated poured lines or veins 3, described in operation (2).

Bonding.

(5.) A mixture of similarly or dilferently colored cement and water or other liquid, with or without the addition of Sand or other aggregate reduced to a senii'liquid consistency, is poured, or placed over the semi-dry, lumpy layer 4 in such a quantity and in such a way as to permit of its percolating or seeping through the layer 4:. This fluid cement makes a bond to fill the voids in the loose lumpy layer except for the pockets. that forms on the surface and serves to bind the portion oi the surface produced by operation (2) with that of the scmidry layer of operation l).

Blotting and drying.

(6.) In the case of the use of Portland (white or standard) or similar slow setting materials containing an aggregate which gives the mass a heavy specific g ty. it is necessary to check the see iiage of material in the binding, coat of step (5), which is done by a sprinkling of dry cement 6, or such a mixture as has been used in any of the previous operations, or a similar combination, over the surface of operation (5). This check is necessary for the purpose of preventing continuing seepage or mixture of operation (5), by gravity, from the entirelv surrounding semi-dry particles of mixtur laid in operation (-1), and thereby destroying the porosity or eli'rct desired in the finished surface of the rust or positive.

In the case of quicker setting material of lesser specific gravity this operation (6) 1S not always necessary.

Reinfiorcemnt.

(7.) Where the foregoing material coatings have not resulted in a cast or positive of sufficient strength, an ordinary mixture 7, of a plastic substance of the same or other ingredients, with or without fiber, may be -vidimif any required-strength in" the cast or dositive by applying this coating after the initial set or'crystallization of previous coats has taken place, thereby not disturbing the position on the surface of the form or mold of the ingredients provided by the previous steps of the process.

In proceeding by process (B), as in the case ofwvalls, ceilings, etc., already erected into position, I employ the following steps: The plastic materials or ingredients, such as Portland cement, Kecnes cement, magnesite, plaster of Paris, or a combination of the ingredients, are applied to walls or ceilings, interior or exterior, whereby the resulting surface obtains a striated porosity of the nature and for the purpose of pro- (lacing ii simulation or imitation of the surface that obtains in Roman travertin stone commonly known as travertin; the object being to incorporate several or all of the following steps in accordance with the degree or perfection in imitation or simulation required in the finished surface from the architects viewpoint:

1. To a concrete, brick, metal or wood lath, or any similar form of construction B, one or two coats of plastic material or mortar, as 10, composed of plaster of Paris, Portland cement or Keenes cement and sand or aggregate, is applied and straightened to a. fair surface, This application may be varied in method and result; the object being to form a foundation for the steps which follow.

2. Next, a. colored mixture, as 11, composed of white Portland cement, Keenes cement, niagncsite, plaster of Paris, or Similar materials. with tor without a percentage of aggregate or sand added, is reduced to a consistency of a. soft paste in semi-liquid form, by the addition of Water or other agency, and applied to the wall in that state by means of a trowel, float or similar device to a varying thickness, in accordance with the depth of porosity required in the finished result. This application is immediately straightened roughly by means of a rule or straight-edge. 2 is for the purpose of producing a background coating of the general color form required, of suflicient thickness to permit of the next operation.

3. One or several mixtures of different colors of the foregoing ingredients, or reduced with water or other liquid to a. soft pasty consistency, is applied in.a series of horizontal veins 12. of varying length, with a. narrow, long, soft brush, or other device immersed in the one or several colored mixtures successively and applied to the coating 11 of operation B abovehy stippling in while the material of coat 11 is very soft. A light horizontal trowel action'is repeatedly applied. This is for the purpose providing light, horizontally striated vins or lines of different colors or tones of color in the finished result.

. While the foregoing coats 1/1 aiid 12 are The foregoing coat still very soft, :1 sharp stipplo is produced to the full depth of coatings 11 and 12 by means of a slender or narrow brush of stiff bristles held horizontally and plied in a sorics of alternating sharp jah and pressure, said stipplr-d jabs being placed staggered, with varying sequence between the rolored reins 12 described heretofore.

5. A light horizontal trowel appliration follows. This is for the purposr ol' produr ingzj the greater porosity in textur markings required in the iinishrd result; tho form and nature of the briz-itlrs producing a jagged series of depressiomg horizontally striatcd formation, and the trowrl't pressure reducing the width of those :lcprr... 'onri, together with providing an undercut quality to the sti ipling it 'u'ould not otherwise havc.

\Vhilc il is still suit. hut in an adimram l pr'wrliingz ol zl'ybtillililutlwii, H111. .ar 'fi i i lulu LE1 applied in a lit: vaid-cl r tatio ii) means ol' a still wire i rus i n ugh to ponetrate tho sin-farm gradua l hardening, and applied between tin gr wn: markings and veins dcsecrihril in oporath is Pi nd i)? This i F r the purpisc of producing the refinements of texture or horizontal strata of porous quality not provided or possible by prior operations described,

7. The snrfacc mixture ll, with its added raining mixture is now finished by the appliration of Yitfi' 'iilifi trowclinn'. This is for the purpose oi remo ing all. imperfec tions, or unevenni that ma accrue during operations B B. B l), R and B, and to lea re a straight si'nooth surface of different color tones produced hr tho variegated. striated veins and the shadows of the do pressions, such are characteristic of Roman travertin or stone commonly known as travertin? 8. In such moldings, cornices, panel moldings, or forms of ornamentation as may re quire it, the same methods are applied in forming the same as described in operations B; B, B, B", B and B except that fol lowing the last step a knife mold that has the form or outline of the object required will o used in addition to the ior'going methm; of B B', B", B, B and B" and run over the surface of the object its full length to retain perfection of contour.

Having thus' described my invention, what I im and desire to secure by Letters Pat- ;in: as"

1. A process for the manufacture of striated. artificial stone structures which comprises depositing upon a prepared surface of desired form a series of narrow layers of plastic material, depositing upon said layers and upon the exposed surfaces hcrebetween a suitable material of such texture and consistency as will leave numerous small ii tij ll portions of said exposed surfaces out of contact with said matcrial, binding togethur said lai'rrs and said material \\ltll a fluid cement. and allowing llu mass to set.

.3. A prom-cs l'or lunnuultactiu'c of striated artificial slunu strurturcs which roinprisrs depositing upon a prepared suri'arc of desired form a snllcs of narrow layers of plastic luau-rial ol a rcrtain color, depositiug: upon said la rrs and upon the exposrd surfaces ihrrebclirrru a suitable n1a trrial of a ditl'rrrut color and oi such tox linre and comsisteiuay 71 will lrarr numerous small portions ol' said rxposed surfaces out of contact with said matcrial, binding to ,qcthcr said layers and said material with a fluid crmrnt. and allowing the mass t set.

22, i. prom-as for tho manufacture of striated artiticial stout utrurluies which rumprisns iirp srtiiig' 11pm n prrparrd s n ta o oi li-sirril torn: a series oi lmlIrAY la)- crs of plastir mute-rial. srrrating' l'uc Highs oi tho layers. depositing upon said layers and up n the rxposrd surtzn-cs tlirrrhrturru a suitabl material of such tcxturu and ronsistenoi as will lcavc nuuicrous small por tions of said exposed surlares out oi contact with said material. binding, together said lui 'ers and said material with a fluid rement. and allowing the mass to 4. A process for the manufacture of striated artificial stonestructures, which consists in dcpositing1 upon a prepared surface a series of veins of plastic material in simulation of the stone otriatious, depositing a loose lun'ipy n'laterial over the ruining material to leave a porous body, binding the foregoing with a iiuid reincnh blotting up the excess seepage oi the binding iluid to prevent all the 'intcrstires in the loose lumpy material from filling up, and allowing the mixture to suit 5. A process for the manufacture of striated artificial stone s1, ructurcs. which consists in preparm u mold of suitable outline with an isolator iorining veins of plastic material over thi prepared surface, depositing loose, lump natcrial over the veining to provide pockets, binding the pocket-forming material with the veining material, and leaving certain pockets exposed on the surface adpicent to the mold surface.

6. A rocess for the manufacture of stria ted art ilicial stone. structures. which consists in preparing a mold of suitable outli I with an isolator, forming veins of plastic, aterial over this prepared surface, stippling the veins to provide a serrated edge ell-cot, de-

ositing loose, lumpy material over the veinmg to provide pockets, binding the pocketforming material with the veining material, and leaving certain pockets exposed on the surface adjacent to the mold surface.

7. A process for the manufacture of striated artificial stone structures, which consists in preparing a mold of suitable outline with an isolator, forming reins of plastic material over this prepared surface, stippling the reins to provide a serrated edge eflect, depositing loose, lumpy material over the veining to provide pockets, binding the pocketforming n'iaterial with a fluid cement, and depositing a drier on the upper surface of the mass to take up the excess seepage and prevent filling; of all the pockets on the surfare next to the mold.

H. A process for the manufacture of striated artificial stone structures, which consists in preparing a mold of suitable outline with an isolator, forming reins of plastic material over this prepared surface. stipplingz the reins to provide a serrated edge elteet, depositing loose, lumpy material over the reiuing to provide pockets, binding the pocket-forming u'iaterial with a fluid Cement, depositing a drier to take up the excess seepage and prevent filling of all the pockets on the surface next to the mold, and reinforcing the structure.

9. A cementitious structure suitable for decorative purposes comprising a mass of cementitious material at least one surface of, which is shaped and striated and formed with small irregularly spaceddepressions, the striac constituting the exposed portions of shallow inlays of uniformly coloredcement.

10. A cementitious combination for decorative use such as a finish for exterior or interior building walls and ceilings, which romhiuation is formed of ditlerently toned thin layers or strata the said layers onl partly connected one to the other in sue manner as to leave serrated voids in stratitied formation between said layers, said layers and voids existing only adjacent to the surface but giving an appearance when erected, of extending through the depth of the mass, the resulting decorative surface sinndating that of a natural stone structure of sedimentary origin.

In testimony whereof I have hereunto set my hand in the presence of two subscribing witnesses.

, PAUL E. DENIVELLE. Witnesses i W. W. HEALEY, M. F. EWING. 

